Prefabricated wall panel with interlocking structure

ABSTRACT

A prefabricated wall panel ( 10 ) has a precast body ( 12 ) including at least one decorative design element ( 14 ). In addition, the wall panel includes a mounting element ( 16 ) having a first end ( 18 ) embedded in the precast body and a second end ( 20 ) projecting from the precast body. A interlocking structure ( 36,40 ) is provided along at least two opposing edges of the wall panel to insure proper alignment and interconnection when two or more wall panels are installed together on a support substrate.

CROSS REFERENCE TO RELATED APPLICATION

The present invention claims priority to U.S. patent application Ser.No. 12/026,876 filed on 6 Feb. 2008 and entitled “Prefabricated WallPanel with Tongue and Groove Construction”, the entirety of which isincorporated by reference herein.

BACKGROUND

Prefabricated or cast veneer wall panels have been developed as a quickand efficient way to provide a masonry appearance for a building whilesimplifying construction and lowering construction cost. The designelements of prefabricated wall panels typically simulate brick, stone,tile and other masonry building components or materials commonly used inthe construction of buildings. Examples of prefabricated wall panels aredisclosed in U.S. Pat. Nos. 3,142,938 to Eberhardt, No. 4,669,238 toKellis et al, 5,379,561 to Saito and 5,673,529 to Treister et al, inpublished U.S. Patent Application Ser. No. 2007/0137128 to Viau et aland in Co-pending patent application Ser. No. 11/647,751 owned by theAssignee of the present invention.

Prefabricated wall panels are typically made from reinforcedconstruction materials such as fiberglass reinforced concrete.Prefabricated wall panels made from such reinforced materials areresistant to damage to handling during packaging, shipping andinstallation. However, further improvements in durability to decreaseloss due to breakage are still desired. The present invention relates toa prefabricated wall panel incorporating a mounting element to enhancedurability and provide significantly improved handling characteristicsas well as tongue and groove construction to simplify installation.

SUMMARY

In accordance with the embodiments of the present invention improvedprefabricated wall panels are provided. The prefabricated wall panelcomprises a precast body including at least one decorative designelement and a mounting element including a first end embedded in theprecast body and a second end projecting from the precast body. Aninterlocking structure is provided along at least two opposing edges ofthe prefabricated wall panel to ensure proper alignment andinterconnection when at least two of the prefabricated wall panels arepositioned together to complete a wall.

In accordance with one possible embodiment of the present invention, theinterlocking structure comprises a cooperating tongue and groovearrangement.

In accordance with yet another possible embodiment of the presentinvention, the interlocking structure includes alternating tonguesstaggered in two rows.

In accordance with yet another possible embodiment of the presentinvention, the interlocking structure comprises a cooperating hook andslot arrangement.

In still another possible embodiment of the present invention, theinterlocking structure comprises edge grooves and an interconnecting pinreceived in those grooves to hold the adjacent wall panels in properposition. In any of these possible embodiments, the interlockingstructure is provided along at least two opposing edges of the precastbody.

In accordance with yet another aspect of the present invention, a wallpanel system is provided comprising a prefabricated wall panel, astarter strip and a trim element.

In the following description there is shown and described severaldifferent embodiments of the invention, simply by way of illustration ofsome of the modes best suited to carry out the invention. As it will berealized, the invention is capable of other different embodiments andits several details are capable of modification in various, obviousaspects all without departing from the invention. Accordingly, thedrawings and descriptions will be regarded as illustrative in nature andnot as restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings incorporated herein and forming a part of thespecification, illustrate several aspects of the present invention andtogether with the description serve to explain certain principles of theinvention. In the drawings:

FIG. 1 is a front perspective view of a prefabricated wall;

FIG. 2 is a cross-sectional view of the prefabricated wall panelillustrated in FIG. 1;

FIG. 3 is a partially schematical and cross sectional view illustratingthe mounting of two wall panels, one above the other, along a supportsubstrate such as a wall stud;

FIGS. 4A-4D are fragmentary front elevational views of four differentmounting elements used in the prefabricated wall panel of the presentinvention;

FIGS. 5A-5G are schematical sectional views illustrating severaldifferent embodiments of the wall panel of the present invention;

FIG. 6 is a cross sectional view of the mold in which the wall panel ofFIGS. 1 and 2 are formed;

FIG. 7A is a perspective view of an alternative embodiment of a wallpanel incorporating an interlocking structure comprising alternatingtongues staggered in two rows;

FIG. 7B is an end elevational view showing the interconnection of twowall panels of the type illustrated in FIG. 7A;

FIG. 8 is an end elevational view showing another alternative embodimentof wall panel incorporating a cooperating tongue and groove arrangementwherein the entire tongue and groove arrangement is formed in theprecast body of the wall panel;

FIG. 9 is an end elevational view of yet another embodimentincorporating two cooperating grooves and a separate pin or biscuit asthe interlocking structure;

FIG. 10 is an end elevational view of yet one more alternativeembodiment incorporating cooperating hooks and slots as the interlockingstructure;

FIGS. 11A and 11B are respective end elevational and front elevationalviews of a starter strip that forms a part of the present wall panelsystem;

FIGS. 12A and 12B are respective end elevational views of the hingedtrim element that forms another part of the present wall panel system.

FIG. 13 is a schematical illustration of two panels overlying a starterstrip against a framed wall of a building;

FIG. 14 is a schematical view illustrating a trim element providedbetween a panel and a window or wall; and

FIG. 15 is a schematical view illustrating a trim element providedbetween a panel and a fascia or soffit of a building.

DETAILED DESCRIPTION

Reference is now made to FIG. 1 illustrating a prefabricated wall panel10. Such a wall panel 10 may be used as a wall cladding for a building.Further applications include but are not limited to the construction ofa fireplace surround or an outdoor living component such as a decorativewall or grill surround.

The prefabricated wall panel 10 comprises a precast body 12 including atleast one decorative design element 14. As illustrated the designelement 14 comprises two rows of overlapping brick with four brick ineach row. It should be appreciated that substantially any other masonrymaterial known in the art may be simulated including bricks of differentsizes, stones of the same or different sizes and shapes, tiles ofdifferent sizes and shapes and the like.

The precast body 12 is made from a cast material such as concrete,reinforced concrete, gypsum, fiber reinforced gypsum, polymer modifiedgypsum, reinforced cementitious material and mixtures thereof. Typicallythe cast material reinforcement comprises fibers selected from glassfibers, carbon fibers, mineral fibers, natural fibers, polymer fibersand mixtures thereof. Where glass fibers are used they may be of theE-glass or AR-glass type which exhibits some alkali resistance.

As best illustrated in FIGS. 1 and 2, the prefabricated wall panel 10also includes a mounting element, generally designated by referencenumeral 16. The mounting element 16 may be made from any suitable amaterial including, but not limited to, wood, concrete, cellulose fiberboard, polymer material, composite material, metal, plastic, reinforcedplastic, thermoplastic, fiber composite, reinforced wood, steel,corrosion-resistant steel, aluminum, stainless steel, zinc, copper andcombinations thereof. The corrosion-resistant steel may take any numberof forms including, but not limited to, galvanized, galvanneal,Gavalume™ brand, tin coating, chromium coating, nickel coating,phosphorous coating, magnesium coating, copper coating, zinc coating,weathering steels (i.e., alloys of steel with small additions of copper,aluminum, nickel and/or phosphorous), polymer coatings and paint.

Polymer materials useful for the making of the mounting element 16include various thermoplastic and thermoset resins including but notlimited to polyolefins, polyesters, polyvinylchloride, polypropylene,polyethylene, polyamide, epoxy, vinyl ester, acrylic, polystyrene, ABS,melamine and mixtures thereof. Composite materials used to make themounting element 16 may include a reinforcing material and a matrixbinder. Appropriate reinforcing materials useful in the presentinvention include but are not limited to glass fibers, natural fibers,mineral fibers, basalt fibers, carbon fibers, kenaf fibers, jute fibers,hemp fibers, E-glass fibers, C-glass fibers, R-glass fibers, S-glassfibers, ECR-glass fibers, AR-glass fibers and mixtures thereof. Itshould be appreciated that substantially any type of glass fiber may beused for reinforcement fibers. Glass fibers appropriate for use in thepresent invention may be loose chopped strand or glass mat and includethose available under the trademark ADVANTEX. Matrix binder materialsuseful for this purpose include but are not limited to polyolefins,polyesters, polyvinylchloride, polypropylene, polyethylene, polyamide,epoxy, vinyl ester and mixtures thereof.

As best illustrated in FIG. 2, the mounting element 16 includes a firstend 18 that is embedded in the precast body 12 and a second end 20 thatprojects from the precast body. This may be accomplished by positioningthe mounting element 16 so that the first end 18 projects into the moldcavity in which the body 12 is cast. After positioning the mountingelement 16, the cast material is sprayed, injected or otherwise added tothe mold. The cast material of the body 12 covers the front and the rearmajor faces of the first end 18 of the mounting element 16. When set,the body 12 securely holds the mounting element 16 in position. In someembodiments, the first end 18 includes a series of spaced keying holes17. These holes 17 fill with the cast material and ensure that themounting element 16 is firmly seated and secured in the cast body 12once the material sets.

As illustrated in FIGS. 1 and 2, the second end 20 of the mountingelement 16 projects upwardly from the top edge of the precast body 12.In the illustrated embodiment, the mounting element 16 includes atransition section 22 connecting the first end 18 with the second end20. In one embodiment, the transition section 22 forms an included angleof between 0° and about 180°. In another embodiment, as illustrated inFIG. 2, the transition section 22 forms an included angle of betweenabout 130° and about 140° or about 135° with the first end 18.

As further illustrated in FIGS. 1, 2 and 3 the second end 20 of themounting element 16 may include a series of protrusions 21. Theprotrusion 21 may take the form of dimples, slots, ribs or any otherstructure that provides a set back means and can receive a nail orfastener. In the illustrated embodiment, the protrusion 21 is a dimple.The dimples 21 project away from the front face 28 of the wall panel 10.The dimples 21 function to provide an air space A between the wall panel10 and the sheathing S or other building substrate to which the wallpanel 10 is fastened. The wall panel 10 is fastened or secured to thesheathing S by means of fasteners such as nails or screws F that arereceived and pass through the recessed apertures 23 provided along thesecond end 20 of the mounting element 16.

In some examples, each dimple 21 has an interior diameter of betweenapproximately 0 and approximately 7.6 centimeters. In other examples,each dimple 21 has an interior diameter of between about 2.5 and about7.6 centimeters. In yet other examples, each dimple 21 has an interiordiameter of between about 2 to about 5 centimeters. In further examples,each dimple 21 has an interior diameter of between about 1.0 and about1.6 centimeters.

Each dimple also has any suitable depth. For example, each dimple 21 mayhave a depth of between approximately 0.30 and approximately 0.60centimeters. The aperture 23 in each dimple 21 may have any suitabledimensions. For example, the aperture 23 may have a diameter of about0.3175 centimeters. Further, the aperture 23 may be concentricallyreceived in the bottom of the dimple 21. In some examples, the diameterof the dimple 21 allows the head of a fastener, such as a roofing nail,to fit inside the dimple where it will not interfere with the mountingof the next panel. The aperture 23 ensures the centering of the nail inthe dimple. The bottom wall of the dimple 21 may also be slightly curvedas illustrated. The size and shape of the dimple 21 ensures that thedimple does not collapse or become embedded in the underlying sheathingduring installation of the wall panel 10. In this way good ventilationis provided between the wall panel and the underlying sheathing to whichit is mounted as discussed in detail below.

In order to complete a wall, it is generally necessary to vertically andhorizontally stack a series of prefabricated wall panels 10. In someexamples, each additional row of wall panels 10 is offset with respectto the previous row by the staggered ends 34 (see FIG. 1) provided onthe panels. As each succeeding wall panel 10 in each succeeding row isadded (see FIGS. 2 and 3), an interlocking structure in the form of atongue and groove arrangement ensures proper placement and greatlysimplifies installation. In other examples, the panels may have asquare, rectangular, or other suitable shape with no staggered ends.

More specifically, each wall panel 10 includes a groove 36 formedbetween the precast body 12 and the front face of the second end 20 ofthe mounting element 16. The groove 36 is provided in or along the firstor top edge 38 of the precast body 12. In the illustrated embodiment, acooperating tongue 40 is formed by the second or bottom edge of theprecast body 12. In alternative embodiments, the tongue 40 could beformed by a metal backer or other similar structure. Duringinstallation, the tongue 40 on one wall panel 10 is precisely sized andshaped to be received in the cooperating groove 36 on the underlyingwall panel 10. This interconnection ensures proper registration betweenwall panels 10 during installation. Further, the tongue and grooveconnection between the wall panels 10 functions to support the wallpanel being added in proper position until fasteners F can be positionedin the support substrate S through the recessed apertures 21 to hold thepanel in place. If desired, grout is then provided in the grout areas 32between the design elements 14 on all of the wall panels 10 in order tocomplete the installation. Weep holes 25 are provided at spacedlocations in the second end 18 of the mounting element 16 adjacent thetransition section 22. These weep holes 25 allow water to drain from thegroove 36. In the illustrated embodiment, a weep hole 25 is provided atthe center of each design element 14. In another embodiment, the weephole 25 may not be at the center of each design element 14.

As best illustrated in FIGS. 4A-4D, the mounting element 16 may take anumber of forms. As illustrated in FIGS. 1, 2, 3 and 4A, the first end18 and second end 20 may both be made from a solid piece of material.Alternatively, as illustrated in FIG. 4B, the two ends 18, 20 may bothbe made from a mesh material (i.e. any perforated material), such as,galvanized steel, aluminum and/or copper. In this embodiment, no weepholes 25 or recessed apertures 21 are provided. It should beappreciated, however, that weep holes 25 and recessed apertures 21 maybe provided if desired. As yet another alternative, FIG. 4C illustratesan embodiment wherein the first end 18 is made from a mesh material andthe second end 20 is made from a solid material. In contrast, FIG. 4Dillustrates an embodiment where the first end 18 is made from a solidmaterial and the second end 20 is made from a mesh material.

The use of mesh material instead of solid material serves a number ofadvantages. Good strength is obtained yet less material is used therebyreducing costs of production. Where the first end 18 is made of meshmaterial, the interlocking of the mounting element 16 in the precastbody 12 is enhanced. This is because the cast material is received inand passes through each of the openings in the mesh to provide a mostsecure interconnection.

Alternative embodiments for the wall panel 10 are illustrated in FIGS.5A-5G. In FIG. 5A, the first end 18 of the mounting element 16 is longenough to extend nearly to the end of the tongue 40. This provides addedstrength to the precast body 12. In this embodiment, the first end 18 ofthe mounting element 16 is made from solid material including a fewspaced keying holes 17 for receiving cast material. In the embodimentillustrated in FIG. 5B, the first end 18 is made from mesh material.

FIG. 5C illustrates a wall panel 10 incorporating a mounting element 16with a second end 20 constructed from mesh material and an extendedfirst end 18 constructed from solid material but incorporating severalkeying holes 17. FIG. 5D illustrates yet another alternative embodimentwherein the entire mounting element 16 is made from mesh materialincluding the first end 18. In FIGS. 5C and 5D, the mounting element 16is illustrated as being formed from a double layer of mesh material.This provides added strength to the mounting element 16.

FIGS. 5E-5G illustrates additional alternative embodiments. In FIG. 5E,the mounting element 16 is made from two separate pieces. It will beunderstood that it could be made of three, four or more pieces ifdesired. The first piece 16 a of the mounting element includes a firstend 18 embedded in the precast body 12 and extending in a first planeP₁, a second end 20 projecting from the precast body 12 and extending ina second plane P₂ and a transition section 22 connecting the first andsecond ends 18 and 20. As further illustrated, the first end may includea keying hole 17 that receives the cast material to ensure that thefirst piece of the mounting element 16 a is securely held in position bythe precast body. The second end 20 includes at least one dimple orother aperture 21 as described above. In addition, the transitionsection 22 includes a slot 70.

As further illustrated in FIG. 5E, a second mounting element 16 b formsa tab 72 projecting from a second edge of the precast body 12. Thesecond piece of the mounting element 16 b, like the first piece of themounting element 16 a, may include a keying hole 17 to receive castmaterial and ensure it is securely held in the precast body 12. Asillustrated, the slot 70 and the tab 72 both extend in a third plane P₃between the first and second planes P₁, P₂. Accordingly, a second wallpanel 10 may be added to a first wall panel 10 previously secured to asubstrate by aligning and inserting the tabs 72 on the second wall panelinto the slots 70 on the first wall panel. Thus, the slots and tabs70,72 function like the tongue and grooves 40,36 on the embodiments inFIGS. 1 and 2 to align and secure wall panels 10 together.

FIG. 5F shows yet another alternative embodiment of the slot and tab70,72 construction. In this embodiment the mounting element 16 is asingle piece incorporating a series of keying holes 17 to allow it to befirmly secured in the precast body 12. This single piece mountingelement 16 provides additional strength to the precast body 12.

In the additional embodiment illustrated in FIG. 5G, a single piecemounting element 16 is again illustrated incorporating the slot 70 andgroove 72 connection system. Unlike the embodiment illustrated in FIG.5F, in the embodiment illustrated in FIG. 5G, a portion 74 of themounting element 16 embedded in the precast body 12 is made from a meshmaterial.

A mold 50 for forming a wall panel 10 is illustrated in FIG. 6. The mold50 comprises a mold body 52 formed from an elastomeric material such assilicone, urethane, polyurethane, and/or latex. The mold body 52includes a mounting element support surface 54, a mold cavity 56 and adimensional flap 58 overlying a portion of the mold cavity that formsthe tongue 40. Sufficient casting material may be added to the mold 50above a lowermost surface 39 of the dimensional flap 58 to insure thegroove 36 is formed to proper shape. More specifically, the mountingelement support surface 54 is provided along a first edge 60 of the moldcavity 56 while the dimensional flap 58 is provided along a secondopposite edge 62 of the mold cavity.

The wall panel 10 is produced by positioning a mounting element 16 ontothe support surface 54 with the first end 18 extending into the moldcavity 56 and the second end 20 extending from the mold cavity. Castingmaterial may be added to the mold cavity 56 before and/or afterpositioning the mounting element 16 onto the support surface 54. Thismay be done by injecting, spraying or any other means known in the art.During this step, the first end 18 of the mounting element 16 isembedded in the casting material.

The method also includes the step of forming the tongue 40 in the moldcavity 56 from casting material captured under the dimensional flap 58.Still further, the method includes forming the groove 36 in the mold 50between the precast body 12 and the second end 20 of the mountingelement 16. After allowing the cast material to set, the wall panel 10is removed from the mold 50. This may be done by stretching the moldbody 52 to free the tongue 40 from under the dimensional flap 58, Itwill be understood that the method and mold may be modified to producethe alternate embodiments illustrated in FIGS. 5A-5G, 7A, 7B and 8-10.

Alternative interlocking structures are illustrated in FIGS. 7A, 713, 8,9 and 10. In all of these embodiments, the mounting element isidentified by reference numeral 16, the precast body is identified byreference numeral 12 and the design element is identified by referencenumeral 14. The mounting elements 16 illustrated do not include dimples21 as described above and illustrated in FIGS. 2 and 3. In theembodiment illustrated in FIGS. 7A and 7B, each wall panel 100 includesalternating tongues staggered in two rows across the top and bottomedges 106, 108 of the wall panel. When two panels 100 are verticallystacked as illustrated in FIG. 7B, the two rows of tongues 102 on eachpanel mate to lock the bottom of the top panel into the top of thebottom panel. This keeps the panels 100 in proper alignment andposition, preventing the bottom of any upper panel from lapping the topof any lower panel. It should also be understood that more than two rowsof tongues and corresponding grooves may be provided.

FIG. 8 illustrates yet another alternative embodiment of wall panel 200wherein the upper edge 202 includes a groove 204 and the bottom edge 206includes a cooperating tongue 208. In this embodiment, the groove 204and tongue 208 are both fully formed in the precast body 210 of the wallpanel 200. FIG. 8 shows how two wall panels 200 are interconnected usingthe cooperating groove 204 and tongue 208 to locate, align and supportthe panels in position when constructing a wall.

Reference is now made to FIG. 9 illustrating yet another embodiment ofwall panel 300 wherein the upper and lower edges 302, 304 of the wallpanel each include a groove 306. A separate pin or biscuit 308 having across sectional area adapted to be received in the aligned grooves 306of the upper and lower edges 302, 304 completes the inner connection ofthese two wall panels 300.

FIG. 10 illustrates yet another embodiment of wall panel 400 of thepresent invention. In this embodiment the top edge or margin 402includes a slot 404 while the bottom edge or margin 406 includes acooperating hook 408. When the two wall panels 400 are interconnected,the hook 408 of one panel 402 is received in the slot 404 of the otherpanel in order to locate, align and support the wall panels 400 inposition when forming a wall.

It will be understood that the side of the wall panels discussed hereinmay contain any suitable interlocking structures. For example, the sidesmay have discontinuous tongue and groove portions that cooperate withtongue and groove portions on adjacent panels.

In accordance with yet another aspect of the present invention, a wallpanel system is provided. The wall panel system includes a prefabricatedwall panel 10, 100, 200, 300 or 400 as illustrated in, for example,FIGS. 1, 7A, 8, 9 and 10, a starter strip 500 as illustrated in FIGS.11A and 11B and a trim element 600 as illustrated in FIGS. 12A and 12B.The starter strip 500 includes a securing leg 502, a support shelf 504,a channel 506 between the securing leg and the support shelf and astabilizing lug 508. Weep holes 507 are provided at spaced locationsalong the bottom of the channel 506. Spaced apertures 510 are providedin the securing leg 502. These apertures 510 receive fasteners (notshown) for securing the starter strip 500 to an underlying substrate orsupport such as the sheathing of a building. When properly mounted tothe sheathing, the face 512 of the securing lug 502 abuts the sheathingas does the end 514 of the stabilizing lug 508. Once the starter strip500 is properly anchored to the sheathing, a wall panel 10, 100, 200,300, 400 is positioned against the face 516 of the securing lug with thelower most edge of the wall panel received and held in the channel 506.In one possible embodiment the support shelf 504 underlies and supportsthe design elements 14 of the wall panel 10.

The trim element 600 includes a substantially j-shaped body 602including a mounting leg 604 and a covering leg 606. The covering leg606 includes a first portion 608 connected to the mounting leg 604 and asecond portion 610 connected to the first portion 608 by an optionalhinge 612. This allows the second portion 610 of the covering leg 606 tobe moved out of the way during installation of wall panels. It will beunderstood that the body 602 may have any other suitable shape. It willbe further understood that the covering leg 606 may be made to beflexible in any suitable manner at any suitable location to allow aninstaller to more easily fit a panel into the trim element.

In use, the trim element 600 is connected to a substrate such as wallsheathing by positioning the face 614 of the mounting leg 604 againstthe sheathing and securing the trim element in position by means offasteners (not shown) received in spaced apertures 616 provided in themounting leg 604. The wall panel 10, 100, 200, 300, 400 is thenpositioned against the face 618 of the mounting leg 604 and the secondportion 610 of the covering leg 606 is pivoted about the optional hinge612 from the position illustrated in FIG. 12B into the positionillustrated in FIG. 12A. This hinged movement of the second portion 610serves to form a wall panel holding channel 620 about the end of thewall panel 10, 100, 200, 300, 400 so as to provide an aestheticallypleasing surface. As illustrated, one or more drain holes 622 may beprovided in the first portion 608 of the covering leg 606 to allowmoisture to drain from the channel 620.

In one possible application a minimum of one layer of grade D buildingpaper or other water resistive barrier (WRB) material is installed overthe sheathing or substrate provided on wood framing. Next verticalframing locations are marked with for example, a pencil or chalk line.It may also be helpful to mark horizontal framing locations in areasaround windows, doors and wall terminations. After this, the installerdetermines and marks the starting point for installation of the wallpanel system. In one application the system must maintain a clearancefrom grade of a minimum of four inches over soil or two inches over ahard surface such as paving or concrete. It is critical that thestarting line be a level line and positioned so that the appropriateclearance from grade is achieved.

Next the installer verifies that the intended starting line provides anequal height distance to overhang, trim or cladding. Once the startinglocation has been determined, the user tacks or tapes WRB material upand marks on the sheathing. The chalk line or pencil line is thenextended across the entire surface to be covered. The user then installsthe starter strip 500 to extend perfectly level along the starting pointline. This is completed by using fasteners such as roofing nails orscrews that are received in the spaced apertures 510. Additionalfasteners may be added to ensure that the channel 506 does not easilypull away from the sheathing along the bottom edge. The WRB material isthen lapped over the securing leg 502. In this position, the WRBmaterial directs any moisture away from the sheathing and toward thechannel 506 from which that moisture can drain from the weep holes 507.

Next the trim element 600 is installed at desired locations aroundwindows, doors and the like. As with the starter strip 500, discussedabove, the trim element 600 is secured in place on the sheathing byproviding fasteners at spaced locations in the apertures 616. As thestarter strip 500 and trim element 600 are subject to expansion andcontraction with temperature change, the user should allow clearance of,perhaps, ¼ inch at all stops or at material abut joints. The fastenersare placed in the center of the elongated apertures 510, 616 and drivenstraight into the sheathing. The fasteners are not nailed tight. Insteada slight clearance is maintained between the fastener head and thestarter strip 500 and trim element 600 so as to more freely allow forexpansion and contraction.

Once the starter strips 500 and trim elements 600 are properly mountedthe wall panels 10, 100, 200, 300, 400 are installed. Generally, cornerpanels are installed before flat panels. Panels 10, 100, 200, 300, 400are installed from bottom to top and lapped in single fashion so thateach seats properly. Further the panels 10, 100, 200, 300, 400 arestaggered from one row to the next to avoid alignment of verticaljoints. Fasteners F are driven straight and flush and panels and cornersare installed level and plum.

More specifically, a flat wall panel 10, 100, 200, 300, 400 ispositioned with the bottom edge (e.g. Tongue 40, 102 or 208 or tab 72)in the channel 506 of the starter strip 500 and the mounting element 16up. The wall panel 10, 100, 200, 300, 400 is then fastened in positionusing fasteners F. In one possible embodiment, two fasteners F mustpenetrate the framing of the building and end fasteners must be locatedwithin three inches of the end of the panel 10, 100, 200, 300, 400 foroptimum anchoring. The next wall panel 10, 100, 200, 300, 400 is thenpositioned into the channel 506 next to the first panel. The installerthen slides the second panel to nest edge to edge with the first paneland fasteners F are installed as previously described. The installercontinues down the wall repeating this procedure until the end isreached. The next course of panels is then started with a half panelimmediately above the first course of wall panels 10, 100, 200, 300,400,

FIG. 13 illustrates the starter strip 500 mounted to the framed wall Wof a building. Two panels 700, 700′ are mounted to the wall W above thestarter strip 500. Note how the tongue 702 on the lowermost panel 700 isreceived in the channel 506 while the design element 704 is supported onthe shelf 504. Also note how the WRB material M laps over the top of thesecuring leg 502 so that moisture is directed into the channel 506 andthen drained away through the weep hole 507.

FIG. 14 illustrates a trim element 600 mounted on a framed wall S of abuilding between a panel 700 and a window or end wall W′. Note how theend 706 of the panel 700 is received in the wall panel holding channel620 formed by the legs 604 and 606.

FIG. 15 illustrates a trim element 600 mounted on a framed wall W of abuilding between a panel 700 and a fascia or soffit S. In thisapplication, the top margin 708 of the panel 700 is received and held inthe channel 620 formed by the legs 604, 606.

The foregoing description of the various embodiments of the presentinvention have been presented for purposes of illustration anddescription. It is not intended to be exhaustive or to limit theinvention to the precise form disclosed. Modifications or variations arepossible in light of the above description. For example, in theillustrated embodiments, the apertures 23 for receiving a fastener areprovided in the protrusion 21. In alternative embodiments, suchapertures 23 may be provided substantially anywhere in the body 12. Asanother example, the illustrated embodiment of FIG. 5E includes amounting element 16 with a first end 18 extending in a first plane P₁and a second end 20 extending in a second plane P₂ where the planes P₁and P₂ are parallel to one another. The mounting element 16 couldinclude ends that extend in planes that are not parallel to one another.

Still further, while the interlocking structures 102, 104, 204, 208,306, 404, 408 are illustrated in only the top and bottom edges of thepanels 100, 200, 300, 400 in FIGS. 7A, 7B, 8A, 8B, 9 and 10, it shouldbe appreciated that like interlocking structures could be provided inthe end or side edges so that the panels interlocked together end-to-endin the same manner if desired. In addition, while the panels 10 in FIG.1 are elongated with staggered ends 34, it should be appreciated thatthey could assume most any shape. For example, the panels 10 could berectangular or square with straight, not staggered ends.

1. A prefabricated wall panel, comprising: a precast body including atleast one decorative design element; a mounting element including afirst end embedded in said precast body and a second end projecting fromsaid precast body; and an interlocking structure provided along at leasttwo opposing edges of said prefabricated wall panel to insure properalignment and interconnection when at least two of said prefabricatedwall panels are positioned together to complete a wall.
 2. The wallpanel of claim 1, further including at least one protrusion in saidsecond end and at least one keying hole in said first end of saidmounting element.
 3. The wall panel of claim 2, wherein said protrusionhas an interior diameter of between approximately 0 and approximately7.6 centimeters.
 4. The wall panel of claim 3, wherein said protrusionhas a depth of between approximately 0.30 and approximately 0.6centimeters.
 5. The wall panel of claim 4, further including at leastone weep hole in said mounting element.
 6. The wall panel of claim 5,wherein said first end of said mounting element extends in a first planeand said second end of said mounting element extends in a second planewherein said second plane is substantially parallel to said first plane.7. The wall panel of claim 6, wherein said mounting element furtherincludes a transition section that connects said first end to saidsecond end and transitions between said first and second planes.
 8. Thewall panel of claim 7, wherein said mounting element is made from amaterial selected from wood, concrete, cellulose fiberboard, polymermaterial, composite material, metal, plastic, reinforced plastic,thermoplastic, fiber composite, reinforced wood, steel,corrosion-resistant steel, aluminum, stainless, steel, zinc, copper, andcombinations thereof.
 9. The wall panel of claim 8, wherein saidmounting element is formed as a solid sheet, as a mesh or as acombination thereof.
 10. The wall panel of claim 1, wherein said precastbody is made from a material selected from a group consisting ofconcrete, fiber reinforced concrete, gypsum, fiber reinforced gypsum,polymer modified gypsum, other cementitious materials and mixturesthereof.
 11. The wall panel of claim 10, wherein said precast bodyincludes reinforcing fibers selected from a group of fibers consistingof glass fibers, carbon fibers, mineral fibers, natural fibers, polymerfibers, E-glass fibers, AR-glass fibers and mixtures thereof.
 12. Thewall panel of claim 1, wherein said interlocking structure comprises acooperating tongue and groove arrangement.
 13. The wall panel of claim1, wherein said interlocking structure includes alternating tongues andgrooves staggered in two rows.
 14. The wall panel of claim 1, whereinsaid interlocking structure comprises a cooperating hook and slotarrangement.
 15. The wall panel of claim 1, wherein said interlockingstructure comprises edge grooves and an interconnecting pin received insaid grooves.
 16. The wall panel of claim 1, wherein said interlockingstructure is provided along at least two opposing edges of said precastbody.
 17. The wall panel of claim 16, wherein said interlockingstructure comprises a cooperating tongue and groove arrangement.
 18. Thewall panel of claim 16, wherein said interlocking structure includesalternating tongues and grooves staggered in two rows.
 19. The wallpanel of claim 16, wherein said interlocking structure comprises acooperating hook and slot arrangement.
 20. The wall panel of claim 16,wherein said interlocking structure comprises edge grooves and aninterconnecting pin received in said grooves.
 21. A wall panel system,comprising: a prefabricated wall panel; a starter strip; and a trimelement; said wall panel system being characterized by saidprefabricated wall panel including; a precast body including at leastone decorative design element; a mounting element including a first endembedded in said precast body and a second end projecting from saidprecast body; and an interlocking structure provided along at least twoopposing edges of said prefabricated wall panel to insure properalignment and interconnection when at least two of said prefabricatedwall panels are positioned together to complete a wall.
 22. The wallpanel system of claim 21, wherein said starter strip includes a securingleg and a channel.
 23. The wall panel system of claim 22, wherein saidtrim element includes a substantially J-shaped body including a mountingleg, a covering leg and a wall panel holding channel.